Devices and methods for three-dimensional printing

Abstract

The present disclosure provides systems and methods for the formation of three-dimensional objects. A method for forming a three-dimensional object may comprise alternately and sequentially applying a stream comprising a binding substance to an area of a layer of powder material in a powder bed, and generating at least one perimeter of the three-dimensional object in the area. The stream may be applied in accordance with a model design of the three-dimensional object. The at least one perimeter may generated in accordance with the model design.

What is claimed is: 
     
         1 . A system for forming a three-dimensional object, comprising:
 a powder dispenser configured to deposit a powder material;   a binding substance applicator configured to apply a binding substance to bind the deposited powder material, wherein the binding substance applicator comprises a binder tank that holds the binding substance and an ultrasonic mist generator system fluidically coupled to the binder tank to deliver the binding substance onto the deposited powder material when the binder tank is filled with the binding substance; and   a perimeter generator configured to generate a perimeter by removing a portion of the powder material bound by the binding substance delivered by the ultrasonic mist generator system based on a model design of the three-dimensional object, thereby generating the three-dimensional object.   
     
     
         2 . The system of  claim 1 , wherein the ultrasonic mist generator system comprises at least one ultrasonic transducer submerged by a specific distance under a surface of the binding substance contained in the binder tank. 
     
     
         3 . The system of  claim 1 , wherein the binding substance applicator comprises a honeycomb structure path through which the binding substance flows. 
     
     
         4 . The system of  claim 1 , wherein the binder tank comprises a float valve configured to control a level of the binding substance. 
     
     
         5 . The system of  claim 1 , wherein the powder material comprises at least one of a metal, a polymer, a metal alloy, a ceramic, or a cermet. 
     
     
         6 . The system of  claim 1 , wherein the binding substance comprises a solvent, a liquid, a gel, a viscous solution, a sugar, a glue, a polymer, or a resin. 
     
     
         7 . The system of  claim 1 , wherein the perimeter generator comprises a contact cutter. 
     
     
         8 . The system of  claim 7 , wherein the contact cutter is a multi-axis machine tool or a computer numeric control (CNC) unit. 
     
     
         9 . The system of  claim 1 , wherein the perimeter generator comprises a non-contact cutter or an air knife. 
     
     
         10 . The system of  claim 9 , wherein the non-contact cutter is a laser. 
     
     
         11 . The system of  claim 1 , further comprising an energy source that is configured to direct an energy beam to a portion of the powder material. 
     
     
         12 . The system of  claim 1 , further comprising a smoother configured to smooth a top surface of the powder material. 
     
     
         13 . The system of  claim 1 , wherein:
 the powder material is a first powder material,   the powder dispenser is a first powder dispenser, and   the system further comprises a second powder dispenser configured to deposit a second powder material to form part of the three-dimensional object, the second powder material being different from the first powder material.   
     
     
         14 . The system of  claim 1 , further comprising one or more computer processors individually or collectively programmed to perform operations including:
 causing the powder dispenser to deposit a layer of the powder material;   causing the binding substance applicator to apply the binding substance to the layer of the powder material; and   causing the perimeter generator to generate, based on the model design of the three-dimensional object, a perimeter corresponding to the three-dimensional object by removing a portion of the layer including the powder material bound by the binding substance.   
     
     
         15 . The system of  claim 14 , wherein the operations further comprise, subsequent to generating the perimeter,
 causing the powder dispenser to deposit an additional layer of the powder material on the layer;   causing the binding substance applicator to apply the binding substance to the additional layer of the powder material; and   causing the perimeter generator to generate an additional perimeter corresponding to the three-dimensional object in the additional layer by removing a portion of the powder material bound by the binding substance, wherein the additional perimeter is based on the model design of the three-dimensional object.   
     
     
         16 . The system of  claim 1 , further comprising a furnace configured to heat the three-dimensional object. 
     
     
         17 . A method for generating a three-dimensional object, comprising depositing, by a powder dispenser, a layer of a powder material;
 applying, by a binding substance applicator, a binding substance to the layer of the powder material, wherein the binding substance applicator comprises a binder tank that holds the binding substance and an ultrasonic mist generator system fluidically coupled to the binder tank to deliver the binding substance onto the deposited powder material when the binder tank is filled with the binding substance; and   generating, by a perimeter generator, a perimeter corresponding to the three-dimensional object by removing, based on a model design of the three-dimensional object, a portion of the layer including the powder material bound by the binding substance.   
     
     
         18 . The method of  claim 17 , further comprising:
 removing unbound powder material from the bound powder material.   
     
     
         19 . The method of  claim 18 , wherein the unbound powder material is removed by a vacuum, suction, or dusting. 
     
     
         20 . The method of  claim 17 , wherein:
 the powder material is a first powder material,   the binding substance applicator is a first binding substance applicator, and   the method further comprises depositing, by a second powder dispenser, a second powder material in the layer, the second powder material being different from the first powder material.